JP2017506159A - Ultrasonic sonotrode for side-by-side transducers - Google Patents

Abstract

For use with techniques for laterally aligning transducers in an ultrasonic welding assembly, the principles disclosed herein are for use in an ultrasonic welding assembly having such laterally aligned transducers. Provide your own ultrasonic sonotrode. In one embodiment, an exemplary ultrasonic sonotrode comprises a body having a nodal region and an abdominal region and is configured to propagate ultrasonic waves received in the nodal region along a first direction. [Selection] Figure 2

Description

  [0001] The present invention relates to ultrasonic welding. More particularly, the invention disclosed herein relates to an ultrasonic sonotrode configured for use with a transducer that is aligned side-by-side in an ultrasonic welding assembly.

  [0002] Ultrasonic welding is a technique employed to join thin malleable materials such as thermoplastics and even soft metals such as aluminum and copper. In the industry, ultrasonic welding is an excellent automated alternative to glue, screw, or snap-fitting techniques that are commonly used to join materials. The advantage of ultrasonic welding is that it takes much less time than conventional adhesives or solvents. The drying time is very short and the pieces do not need to stay in the jig for a long period of time while waiting for the joint to dry or harden. The ultrasonic welding process can be easily automated to produce clean and accurate joints that require little rework. The low thermal shock to the materials involved also allows a larger number of materials to be welded together. In addition, since no glue or other additives are employed during processing, ultrasonic welding is the welding of food-based packages, such as plastic or aluminum bags like the types employed for chips and other snacks. Is a great choice for.

  [0003] During an ultrasonic welding process, a part is placed between a fixed shape nest (called "anvil") and a sonotrode (called "horn"). The sonotrode is connected to a transducer, which is used to convert electrical energy into acoustic vibrations. Such low amplitude acoustic vibrations are emitted from the sonotrode into the material being welded at the intended joint location. Typical frequencies used in ultrasonic welding range from 15 kHz to 40 kHz, but in some cases as high as 70 kHz can be seen. The ultrasonic energy melts the contact points between the parts and creates a joint. Ultrasonic welding works by causing local melting of the material due to absorption of vibration energy introduced across the joint to be welded. In order to ensure that the joint being welded is in the desired location and is the correct size, the interface of the two materials can be specially designed to centralize the melting (welding) process. Although some heating occurs in the joint area, this is usually not sufficient to melt the material, and instead it is introduced along the joint being welded to cause the material to weld together. It is vibration.

  [0004] Applications of ultrasonic welding are wide and found in many industries, including electrical, computer, automotive, aerospace, medical, and packaging. Whether two articles can be ultrasonically welded is determined by their thickness. Therefore, if the material is too thick, the ultrasonic welding process will not join them. Advantageously, the ultrasonic welding process is very time consuming and easily automated and the welding time is often less than 1 second. There is also no ventilation system required to remove heat or exhaust, which helps to reduce the overall manufacturing costs. In addition, ultrasonic welding is very suitable for assemblies that are usually too small, too complex, or too delicate or dangerous for more general welding techniques.

[0005] In the food industry, ultrasonic welding is considered preferred over conventional joining techniques because it is time consuming, hygienic and can create a hermetic seal. An exemplary conventional ultrasonic welding assembly 100 is shown in FIG. This conventional assembly 100 includes an ultrasonic sonotrode 110 to provide acoustic vibration for ultrasonic welding. Acoustic vibrations are introduced into the sonotrode 110 using the ultrasonic transducer 120 and propagate along the longitudinal axis L ₁ of the assembly 100. As described above, the ultrasonic transducer 120 converts the electrical input 125 into acoustic waves, which can then be amplified using the amplifier 130. The ultrasonic sonotrode 110 includes a weld region 115, which in this example is a weld edge 115, which is ultrasonic welded during propagation of acoustic vibrations through the sonotrode 110 toward the weld edge 115. Contact material 140 to be made.

[0006] To ultrasonically weld the material 140, the sonotrode 110 is moved so that the weld edge 115 contacts the material 140 and pushes it against the anvil 150 while propagating therethrough. It oscillates. As shown, the conventional assembly 100, the direction related to welding using the converter 120, the welding edge 115 of the amplifier 130, and the sonotrode 110 is located on the longitudinal axis _{L 1} and the same line, thus the acoustic waves, It propagates along the single axis L ₁ throughout the assembly 100. While the material 140 is pressed against the anvil 150, the oscillation of the weld edge 115 onto the material 140 causes the material 140 to be ultrasonically welded.

While [0007] unfortunately, since the transducer 120 and the welded edge 115 is positioned along a single longitudinal axis L _1, there is a case where premature failure of the ultrasonic welding assembly 100 may occur. More specifically, during ultrasonic welding, the oscillating weld edge 115 is pressed against the anvil 150 (with the material 140 therebetween), so that the physics of the oscillating sonotrode 110, the material 140, and the anvil 150 are Vibration feedback caused by mechanical contact propagates through the sonotrode 110, back through the amplifier 130, and finally back into the transducer 120. Vibrations fed back into the transducer 120 consistently lead to premature failure of the transducer 120. In addition, the linear arrangement of conventional ultrasonic assemblies occupies a large amount of space within the ultrasonic welding apparatus. Furthermore, such a linear arrangement requires that the assembly 100 move toward and away from the anvil 150 for each occurrence of ultrasonic welding of the material 140. Such movement is not only time consuming but also requires additional mechanical equipment and energy to repeatedly move the assembly 100 back and forth for each welding operation. Such additional equipment and energy also results in increased costs and potential equipment failures as a result of such conventional approaches. In view of such shortcomings, there is a need in the art for improved ultrasonic welding apparatus and methods that do not have the difficulties due to the drawbacks found in conventional ultrasonic assemblies.

  [0008] The purpose of the disclosed principle is to result in cracked or damaged sonotrode horns and transducers, non-uniform displacement, or system resonance when the sonotrode assembly is subjected to severe operating conditions. Is to avoid potential problems. Co-pending U.S. Patent Application No. 14/166, entitled “Transverse Sonotro Design Design for Ultrasonic Welding,” filed Jan. 28, 2014, and incorporated herein by reference. , 081 (Attorney Docket Number CFLAY.00878), in ultrasonic assemblies, one or more transducers are “disconnected” from the direction of actuation displacement, and the welded assembly is placed in the nodal region of the sonotrode New techniques are introduced that drive and take advantage of the Poisson effect. As discussed above, in applications that require high forces or high amplitudes, the ultrasonic transducers can be activated during load, i.e. during physical contact with an anvil or other instrument. Considerable stress can be expected. Such mechanical shocks typically produce a reflected wave back into the transducer, which results in an electrical shock to the assembly and system, ultimately leading to a catastrophic failure. By aligning the transducers side-by-side as disclosed in this co-pending application, the ultrasonic welding assembly is superposed on the workpiece or material by the side-by-side mounting arrangement provided by the disclosed principles. It is no longer exposed to feedback that results in damage resulting from the delivery of sonic energy.

  [0009] For use with techniques for laterally aligning transducers in an ultrasonic welding assembly, the principles disclosed herein may be used in ultrasonic welding assemblies having such laterally aligned transducers. To provide its own ultrasonic sonotrode. In one embodiment, an exemplary ultrasonic sonotrode comprises a body having a nodal region and an abdominal region and is configured to propagate ultrasonic waves received in the nodal region along a first direction. Such an exemplary sonotrode is a plurality of direction change features formed in a body, wherein received ultrasonic waves propagating along a first direction are transmitted to one or more of the direction change features. And a direction change feature configured to propagate along a second direction perpendicular to the first direction when impacted by the. In such embodiments, the body is further configured to stretch and compress along the second direction based on the corresponding wave peaks and valleys propagating along the second direction. Such a sonotrode may also include at least one ultrasonic welding surface configured to oscillate based on stretching and compression in the abdominal region of the body.

  [0010] In some embodiments, an ultrasonic sonotrode as disclosed herein comprises a body comprising an elongated structure having an abdominal region along the long side of the elongated structure and a nodal region along the short side. Further may be included. In some embodiments, the opposite ends of the sonotrode comprise nodal regions, and at least one of these opposite ends is configured to receive ultrasound. In a related embodiment, the redirecting feature comprises an elongated slot formed through the body and extending along the second direction. In such embodiments, the elongated slots can be substantially equally spaced across the body. In some embodiments, the elongated slots each comprise a substantially equal width along each slot length. Further, in some embodiments, the elongated slots have various lengths. Still further, in some related embodiments, the length of the elongated slot closer to the end of the body is greater than the length of the elongated slot farther from the end of the body.

  [0011] In some embodiments, the thickness of the body tapers from a central portion of the body extending along the first direction to the edge of the body along the second direction. In some related embodiments, the body edges each comprise a body belly region having a substantially uniform thickness along its length, at least one of these belly regions being At least one welding surface. Also, in some exemplary embodiments, the central portion of the body has a uniform thickness along the first direction, and the taper extends from the central portion of uniform thickness to the edge.

  [0012] Other aspects, embodiments and features of the present invention will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying figures. The accompanying figures are schematic and are not intended to be drawn to scale. For purposes of clarity, not every component is labeled in every figure, and each embodiment of the present invention is not necessary to enable those skilled in the art to understand the present invention. All components of are not shown. All patent applications and patents incorporated herein by reference are incorporated by reference in their entirety. In case of conflict, the present specification, including definitions, will control.

  [0013] Novel features believed to be characteristic of the invention are set forth in the appended claims. However, the invention itself, as well as the preferred mode of use, further objects and advantages of the invention, will become apparent by reference to the following detailed description of exemplary embodiments when read in conjunction with the accompanying drawings, in which: Will be best understood.

[0014] FIG. 1 depicts one embodiment of a conventional ultrasonic welding assembly. [0015] FIG. 6 depicts one embodiment of an ultrasonic welding assembly constructed in accordance with the disclosed principles. [0016] FIG. 2 is a diagram of half the wavelength (λ / 2) of acoustic vibrations oscillating through its material along its longitudinal axis. [0017] FIG. 5 is a diagram of a material that undergoes the Poisson effect during the entire wavelength (λ) of acoustic oscillation. [0018] FIG. 1 is a side view of a conventional ultrasonic welding assembly having a single acoustic wave transmission line geometry. [0019] FIG. 5 is a perspective view of an ultrasonic welding sonotrode constructed in accordance with the disclosed principles. [0020] FIG. 7 is an end view of the ultrasonic sonotrode shown in FIG. [0021] FIG. 8 is a side view of the ultrasonic sonotrode shown in FIGS. 6 and 7; [0022] FIG. 6 is a perspective view of an ultrasonic welding assembly incorporating an ultrasonic sonotrode constructed in accordance with the disclosed principles.

  [0023] The disclosed principle improves the weldability of thin materials with an ultrasonic system by incorporating a unique ultrasonic welding sonotrode design and structure, and is novel for producing such a unique ultrasonic sonotrode. With method. The disclosed principle provides a sonotrode that can be employed with side-by-side mounted ultrasonic transducers, where such side-by-side alignment results from load conditions found at the weld surface of the assembly. , Resulting in disconnection of the acoustic wave transmission axis of the transducer. Accordingly, a sonotrode according to the disclosed principle provides an oscillation that oscillates in a transverse direction with respect to an acoustic wave input to the sonotrode. More particularly, with respect to ultrasonic welding applications, the disclosed principles include acoustic vibrations derived from the antinode of a first waveguide of an ultrasonic assembly (eg, an amplifier) and propagating along a first transmission axis, When a node of the second waveguide is coupled to the antinode of the first waveguide, along the second transmission axis perpendicular to the first transmission axis in the second waveguide (eg, sonotrode) And transforms it into a propagating vibration. For ultrasonic welding applications, the disclosed principle is in contrast to the conventional practice, by coupling the sonotrode node region to the transducer / amplifier abdominal region relative to the transmission axis of the transducer / amplifier assembly. A sonotrode having a weld surface that is vertical.

  [0024] Turning to FIG. 2, an ultrasonic assembly 200 having a sonotrode constructed in accordance with the disclosed principles is shown. The disclosed assembly 200 includes an ultrasonic sonotrode 210 to facilitate ultrasonic welding of the material 240. In this illustrated embodiment, the sonotrode 210 includes two weld regions or surfaces 215a, 215b that are on opposite sides of the sonotrode 210. Of course, in other embodiments, the sonotrode 210 may include a greater or lesser number of weld areas, as each particular ultrasonic welding application may require.

[0025] In this illustrated embodiment, the sonotrode 210 in that it may be rotated about its longitudinal axis L _1, which is sonotrode rotary. In order to ultrasonically weld material 240, weld areas 215 a, 215 b press material 240 against anvil 250. In this exemplary embodiment of the rotary anvil 250 may rotate about its longitudinal axis L _2. More specifically, rather than moving the sonotrode 210 sideways toward and away from the anvil 250, as in a conventional assembly as shown in FIG. Both the sonotrode 210 and the anvil 250 can simply be rotated to grip the material 240 to be welded between them. After ultrasonic welding is performed, rotation of the sonotrode 210 and anvil 250 can release the material 240, and the material 240 is then placed in another area of the material 240 between the sonotrode 210 and the anvil 250. It can be advanced to get and thus welded. Of course, the disclosed principles can be applied to non-rotary weld assemblies as well, and is not intended to be a limitation on this exemplary embodiment.

[0026] Looking more closely at how an ultrasonic welding process may occur using the assembly 200 in FIG. 2, the illustrated ultrasonic welding assembly 200 transforms incoming electricity 225 into acoustic vibration. And an ultrasonic transducer 220 for conversion. In the illustrated embodiment, the transducer 220 is a high power ultrasonic transducer 220 that can operate between about 15-100 kHz when converting electrical energy into mechanical oscillation (ie, acoustic vibration). When the acoustic wave is generated, this wave toward the transducer 220 to the sonotrode 210 and propagates along the longitudinal transmission shaft L _1. In high power embodiments, the converter 220 may be powered by a generator that can drive the system on the order of 10,000 watts. Of course, other oscillating frequencies and drive powers may also be employed with respect to systems or methods implemented in accordance with the disclosed principles, and the examples discussed herein are intended to illustrate the disclosed principles in any particular embodiment. Should not be read to limit.

  [0027] Coupled to the transducer 220 is an amplifier 230, which may be employed to adjust the gain (eg, amplitude) of the ultrasound assembly 200. More specifically, the amplifier 230 is simplified in that mechanical oscillations are typically provided (by a transducer) at one belly of the material and then transmitted through a second belly of material, usually at a tuned amplitude. This is a form of sonotrode. For example, a typical 20 kHz transducer may have a displacement output between 28 μm peaks for acoustic waves. With a 1: 1 gain amplifier, the displacement in the first antinode (at the input of the amplifier) will have this 28 μm amplitude, while the displacement in the second antinode (at the output of the amplifier) will also be 28 μm. Amplitude. However, when a 1.5: 1 gain amplifier is employed, the resulting displacement at the amplifier output is 42 μm, which is 1.5 times the gain for the 28 μm amplitude input to the amplifier. . Conversely, if the application requires, an amplifier can be employed to reduce the amplitude of the acoustic wave propagating through the material.

  [0028] Another object of the amplifier is to provide a means to hold the ultrasonic sonotrode transmission line or transmission shaft stationary so that a force (caused by oscillation) can be applied that is appropriate for ultrasonic welding applications. It is to be. In conventional ultrasonic welding assemblies, this is achieved by creating a special geometry around the amplifier nodal region such that the coupling point has a theoretically zero displacement. This approach can be better understood by understanding the physical effects on materials caused by the introduction of acoustic waves, provided below.

[0029] Turning briefly to FIG. 3, a diagram 300 depicting a half wavelength (λ / 2) of an acoustic vibration 310 that oscillates through material 320 along its longitudinal transmission axis L ₁ is shown. ing. The acoustic wave 310 propagates in the X direction through the material 320, where the oscillation of vibration induces stress on the material 320 as indicated by the stress curve 330. More specifically, the peaks and valleys of the vibration wave 310 define the antinodes of the material 320, while the transition of the waves 310 occurs at the nodes of the material 320, and in these antinode regions, theoretically on the material 320. Produces zero stress. As a result, as the acoustic wave 310 propagates through the material 320, there is a stress that compresses and stretches (ie, axially displaces) the material 320 around the nodal region. This phenomenon is called the “Poisson effect”, which is the compression and extension of an elastic solid resulting in a bulging and shrinking effect around the nodal location of the material. For example, FIG. 4 shows a diagram 400 of a material 420 that undergoes the Poisson effect during the entire wavelength (λ) of the acoustic oscillation 410. The peaks and troughs of the wave 410 impart tensile / compressive stress to the material 420 as the acoustic wave 410 propagates through the material 420. This continuous compression and extension provides drive to the sonotrode in the ultrasonic welding assembly.

  [0030] Thus, in a conventional ultrasonic welding assembly, the sonotrode transmission shaft utilizes the abdominal region as a drive point for maximum displacement of the weld edge. Also, on the extension line, amplifiers such as “amplifier rings” have a small level of vibration produced in a radial fashion around the nodal region of the amplifier, so that at this location to provide acoustic waves to the sonotrode It is possible to firmly clamp the transmission lines of the components used. As a result, conventional ultrasonic acoustic transmission lines typically incorporate multiple half-wave (λ / 2) sections and drive ultrasonic vibrations through all of the components of the ultrasonic welding assembly, including the sonotrode. It is like that. Thus, the sonotrode in the conventional assembly is coupled to the second (output) antinode of the amplifier (via its antinode as shown in FIG. 6) and the acoustic energy is applied to the opposing antinode at the weld edge of the sonotrode. As a result, ultrasonic energy is introduced into the material.

  [0031] FIG. 5 shows a side view of a conventional ultrasonic welding assembly 500 having a single acoustic wave transmission axis / line geometry. More particularly, assembly 500 is configured to couple transducer 510, amplifier 520, transducer interface 530 that couples transducer 510 and amplifier 520, and amplifier 520 to an ultrasonic sonotrode (not shown). Sonotrode interface 540.

[0032] As illustrated, each component in assembly 500 provides one-half wavelength of the transmission line. The size and geometry of each component in the assembly 500 is selected based on the application. Thus, the acoustic wave component transmission line may be more complex, including more components at half wave (λ / 2) intervals. Significantly, in this conventional arrangement, the transducer 510 is again coupled to the amplifier / sonotrode's antinode, so that along the centerline transmission axis L ₁ of each half-wave (λ / 2) component. Longitudinal vibration 550 is introduced. Longitudinal vibrations 550 are continuously transmitted through each component and ultimately at the point of the final belly for delivering ultrasonic energy into the sonotrode and thus into the workpiece or material. delivering a longitudinal displacement along a single transmission shaft L _1. Then, according to conventional practice, the assembly 500 is coupled to an ultrasonic sonotrode at the belly of the sonotrode.

  [0033] However, in contrast to conventional approaches, the disclosed principles provide a unique sonotrode that is coupled to the amplifier's antinode (ie, output) at the node point rather than at the sonotrode's antinode point To do. FIG. 6 shows a perspective view of an exemplary ultrasonic sonotrode 600 constructed in accordance with the disclosed principles. The disclosed principle provides a sonotrode for use with techniques for aligning transducers side-by-side in an ultrasonic weld assembly or similar assembly.

  [0034] In the illustrated embodiment, the ultrasonic sonotrode 600 includes a body 610 having both a nodal region and an abdominal region. The body 610 is constructed of a material that allows acoustic waves to propagate through the body 610. For example, the body 610 can be constructed from a metal, such as aluminum or steel, that typically allows easy propagation of ultrasound. Of course, the use of metal for the body 610 is exemplary only, and thus other advantageous materials that either exist or are developed in the future may be employed.

  [0035] As discussed above, typically an object will have a nodal region and an anti-node region, and the response at these points of the material comprising the object will depend on the wave propagating through the object. Will react in various ways. When the frequency of a wave passing through a material with this object is resonating with that material, the Poisson effect results in the expansion and contraction of the material resonating with the propagating wave peaks and troughs. Become. Thus, as discussed above, during the Poisson effect, maximum expansion and contraction will occur in the material belly. In a sonotrode 600 constructed in accordance with the disclosed principles, the sonotrode 600 belly will thus be provided with a welding surface 620, which is where maximum oscillation will occur. However, in contrast to a conventional sonotrode, a sonotrode according to the disclosed principle is coupled to the remainder of an ultrasonic welding assembly (not shown) in the section of the sonotrode 600 and thus receives ultrasonic waves therefrom. Configured as follows.

  [0036] Importantly, coupling the sonotrode 600 at its node, not its belly, results in the weld surface 620 being aligned perpendicular to the direction of the incoming wave. As a result, the disclosed principles result in a “direction change” in the direction of propagation of incoming waves that propagate properly toward the belly of the sonotrode 600 and thus toward its welding surface 620. Like that. FIG. 6 shows the first propagation direction of the incoming wave as D1, and the second propagation direction perpendicular to the first propagation direction as D2. In order to create a change in wave propagation from the first direction D1 to the second direction D2, the disclosed principles further provide a plurality of direction change features 630 formed in the body 610. The direction change feature 630 is formed along the second direction D2 and collides received ultrasonic waves propagating along the first direction D1 with one or more of the direction change features 630. Then, it is propagated along the second direction D2.

  [0037] Depending on the embodiment, the redirection feature 630 may comprise an elongated slot 630 formed through the body 610 and extending along a second direction, as depicted in the embodiment of FIG. . In such embodiments, the elongated slots 630 can be substantially equally spaced across the body 610, as also shown. However, in other embodiments, the direction change feature may have other shapes and may be a multi-directional feature instead of a straight line. Further, in the illustrated embodiment, each elongate slot 630 comprises a substantially equal width along the length of each slot 630. However, the disclosed principles are not so limited. Thus, features of various widths can also be constructed in the sonotrode 600 as long as the feature provides an incoming wave redirection as discussed herein.

  [0038] Still further, the elongated slot 630 shown in FIG. 6 comprises various lengths. Specifically, the length of the elongated slot closer to the end (node region) of the main body 610 is larger than the length of the elongated slot farther from the end of the main body 610. Again, this is not essential. Thus, in addition to potential variations in width and overall direction, the length of the slot 630 or other feature along the second direction D2 can be varied as needed. For example, in the illustrated embodiment, the outermost slot is longer than the innermost slot so that a good direction of ultrasound entering the sonotrode 600 from its opposite ends (ie, nodal regions) A sonotrode 600 that results in a change is obtained. However, in an alternative embodiment, a sonotrode as disclosed herein can have the longest feature length on only one end, while the last feature at the opposite end. The part can be made the shortest, which can lead to a better redirection of waves that come only from the end of the node with the shortest feature length. Thus, as before, the feature shape can be selected to most efficiently redirect incoming waves from the sonotrode node to the belly, as well as the feature length as well. Can be selected to increase the efficiency of the.

  [0039] Thus, the illustrated embodiment of the sonotrode 600 is an elongate structure having an abdominal region along the long side of the elongate structure and a nodal region along the short side, but of the sonotrode according to the disclosed principles It should be noted that other embodiments may have different or alternative shapes. Moreover, nothing in the principles disclosed herein limits the overall shape of the sonotrode to one that is substantially rectangular. Instead, the disclosed principles change so that incoming ultrasound propagating in one direction propagates along the second direction so that the sonotrode can be mounted side-by-side on the assembly that generates and provides the waves Provide any sonotrode shape or configuration that makes it possible. By providing a sonotrode that can be aligned side-by-side with the wave generation assembly, the disclosed principle uses the sonotrode node position as a driving location for incoming acoustic waves, as opposed to conventional practice, As a result, the transducer is “disconnected” from the sonotrode by providing a transverse transmission axis. Thus, longitudinal waves are created in the sonotrode that oscillate transversely to the input displacement provided along the transducer / amplifier transmission axis. Stated another way, separating the output transmission direction D2 from the input transmission direction D1 by aligning the sonotrode belly region side-by-side with respect to the input component means that the assembly according to the disclosed principle is an anvil or It makes it possible to avoid normally destructive feedback from the weld edge 620 that affects other receiving surfaces. Such an approach results in little or no feedback returning from the weld edge 620 of the sonotrode 600 through the transducer, thereby eliminating feedback stresses that promote system failure in conventional ultrasonic welding techniques. To do.

  [0040] Turning now to FIG. 7, an end view of the ultrasonic sonotrode 600 shown in FIG. 6 is shown. From this end view, the unique profile of the sonotrode 600 can be seen. More specifically, the thickness of the body 610 of the sonotrode 600 tapers from the central portion 640 of the body 610 extending along the first direction D1 to the edge 620 of the body 610 along the second direction. It is said. Depending on the embodiment, the taper along the second direction D2 from the central portion 640 can be straight, or they can have a slight radius as in the embodiment shown. Can have. By providing such a taper, the concentration of the wave redirected to propagate in the second direction D2 can be concentrated toward the welding surface 620 of the sonotrode 600. Also, in some exemplary embodiments, the central portion 640 of the body 610 can be constructed to have a uniform thickness along the first direction D1, as also shown. In such an embodiment, the taper extends from this flat central portion 640 of uniform thickness to the edge 620 of the sonotrode 600. Alternatively, a taper of the surface of the sonotrode 600 need not be provided.

  [0041] Turning now to FIG. 8, a side view of the ultrasonic sonotrode shown in FIGS. 6 and 7 is depicted. From this side view, the central portion 640 of this embodiment of a sonotrode 600 as disclosed herein may be better seen. In addition, the uniform width of the redirecting slot 630 in this embodiment can also be seen. However, as discussed above, the size and shape of such features is exemplary only, and thus the disclosed principle is modified to propagate in one direction and then propagate in the second direction. To any sonotrode design and structure, and shape and configuration that allows the incoming ultrasonic wave to be mounted side by side on a transducer assembly that generates and provides the ultrasonic wave And get.

  [0042] To illustrate the disclosed principles, FIG. 9 depicts a perspective view of an ultrasonic welding assembly 700 incorporating an ultrasonic sonotrode constructed in accordance with the disclosed principles. As discussed in detail below, the output displacement of the unique ultrasonic sonotrode is transverse or perpendicular to the input longitudinal displacement of the incoming acoustic wave.

[0043] The assembly 700 in FIG. 9 includes a converter 710, an amplifier 720, and a sonotrode 730. However, both the structure and positioning of the assembly components are significantly different from conventional approaches. Specifically, the transducer 710 and the amplifier 720 are configured along the same longitudinal transmission axis L ₁ , but these components may be considered as “sides” of the sonotrode 730 where Connected. The side of the sonotrode 730 includes its knot region as shown. Thus, welded edges 735a of the sonotrode 730, 735b is arranged configured along a second transmission shaft _{L 2,} in this case, transmission shaft _{L 2} of the second, to the first transmission shaft _{L 1} It is vertical.

[0044] With this innovative arrangement of components, the acoustic wave generated by the transducer 710 and amplified by the amplifier 720 propagates along the _first transmission axis L ₁ and is amplified at the antinode. Exit from 720. These acoustic waves are input to the sonotrode 730 in the nodal region rather than in its abdominal region as is done in the conventional technique. For example, a half-wavelength (λ / 2) converter 710 is tightly coupled to a node position at a quarter-wavelength (λ / 4) of a half-wavelength (λ / 2) sonotrode 730. This may be due to the purpose of generating a longitudinal wave transverse to the drive direction of the transducer 710 via the coupled sonotrode 730. Stated another way, the disclosed principle is the resonance at half wavelength (λ / 4) of the half wavelength (λ / 2) of the sonotrode 730 corresponding to the node of the sonotrode 730. To force. As a result, the expansion / contraction cycle that is effected relative to the nodal position begins to drive the sonotrode 730 in an outward manner, so that the welding surface 735a of the sonotrode 730 is transverse to the drive direction of the original transducer 710. , 735b is created. This is accomplished by coupling the sonotrode 730 at a quarter-wave (λ / 4) point (shown via the displacement line) that is a node, not its belly.

[0045] A sonotrode 730 constructed in accordance with the disclosed principles is a weld edge that propagates along the _second transverse axis L2 of the input wave, and thus is the belly of the sonotrode 730 for ultrasonic welding applications. Specially designed to facilitate output at 735a, 735b. The size and geometry of the sonotrode configured to be implemented using the disclosed principle is selected based on the application and the amount of displacement required. Furthermore, the two weld edges 735a, 735b provided on the sonotrode 730 of FIG. 9 can be applied for use in a rotary weld assembly, such as the assembly 200 shown in FIG. In such an application, the first transmission line L ₁ is not only the input transmission axis for the generated acoustic wave, but also the axis around which the sonotrode 730 can be rotated in such an embodiment. Of course, it will be appreciated that any number of weld edges may be provided for a sonotrode as disclosed herein, and the disclosed principles are not limited to such rotary applications. Should be.

[0046] In an additional embodiment, a rotary ultrasonic welding assembly 700, such as the type shown in FIG. 9, is a nodal region of the sonotrode 730 opposite the nodal region that receives the transducer / amplifier component. A structure 740 coupled above may also be included. In some embodiments, the opposite structure 740 can be a simple support structure similar to a mandrel for providing support to the opposite nodal region of the sonotrode 730. In other embodiments, the opposite side of the structure 740 will provide two inputs along the same input transmission shaft L ₁ to the sonotrode 730, be a second transducer and / or amplifier assembly it can. In such an embodiment, the power supplied to the two converters can be halved and one half is provided to each converter. Further, in the two transducer embodiments, ultrasonic input from opposite ends of the sonotrode 730 facilitates uniform wave distribution across the sonotrode 730 and thus to the welding surfaces 735a, 735b. Result in In the embodiment shown in FIG. 9, the sonotrode 730 is designed and geometrical to promote uniform wave distribution from a single transducer that delivers waves from only one end (ie, the nodal region). However, in a two transducer embodiment, the sonotrode 730 may have different designs and geometries based on opposing ends / inputs, where these opposing ends are sonotrode The knot region is provided. However, in all embodiments, the principle disclosed in the two transducer embodiments is still the extension and compression of the sonotrode 730 to oscillate the welding surfaces 735a, 735b to a degree sufficient for ultrasonic welding applications. , Along the transmission axis L ₂ which is transverse or perpendicular to the input transmission axis L ₁ .

  [0047] In summary, conventional techniques for ultrasonic welding function using the sonotrode belly as the driving location for the input acoustic wave. As already mentioned, the introduction of ultrasonic energy according to conventional practice occurs in the belly because it is the position with the highest displacement but less stress. However, the disclosed principle teaches contrary to conventional practice, in which case, in order to achieve uniform weld edge displacement even under severe operating conditions, Sonic energy is introduced at the node position (lowest displacement and highest stress).

[0048] The disclosed principles are further conventional in that, using the disclosed principles, ultrasonic energy is introduced transversely (ie, perpendicular) to the load or vibration direction within the sonotrode. Teaching that is contrary to customary practice. In conventional assemblies, the transducer and sonotrode are configured along the same transmission line or transmission axis as discussed above. Unfortunately, as discussed above, this single axis configuration results in significant vibration feedback from the sonotrode to the transducer, which usually leads to premature catastrophic assembly failure . The disclosed principle is that the sonotrode node position as a driving location for incoming acoustic waves to “disconnect” the transducer from the sonotrode by providing a transverse transmission axis, in contrast to conventional practice Is used. Thus, a longitudinal wave is created in the sonotrode that oscillates transversely to the input displacement provided along the transmission axis of the transducer. Stated another way, separating the output transmission axis L ₂ from the input transmission axis L ₁ by aligning the sonotrode's ventral region side-by-side with respect to the input component means that the assembly according to the disclosed principle is: It makes it possible to avoid normally destructive feedback from weld edges that affect the anvil or other receiving surface. Such an approach results in little or no feedback returning from the sonotrode weld edge through the transducer, thereby eliminating feedback stresses that promote system failure in conventional ultrasonic welding techniques.

  [0049] While various embodiments in accordance with the principles disclosed herein have been described above, it should be understood that these are presented by way of example only and not limitation. Accordingly, the breadth and scope of the present disclosure should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with any claims arising from the present disclosure and their equivalents. Moreover, while the advantages and features described above are provided in the described embodiments, they limit the application of such published claims to steps or structures that achieve any or all of the advantages described above. is not.

[0050] In addition, the headings of items herein are 37C. F. R. In accordance with the provisions in 1.77, otherwise provided to provide knitting clues. These headings shall not limit or characterize the invention described in any claim that may be issued by this disclosure. Specifically, and by way of example, these headings have a “technical field”, but the claims selected are limited by the expressions selected under this heading to describe the so-called field. Absent. Furthermore, the description of technology in “Background” is not to be construed as an admission that a particular technology is prior art to any embodiment in the present disclosure. Neither is the "Summary" to be considered as a characterization of the embodiments described in the appended claims. Moreover, any reference to “invention” in the present disclosure should not be used to claim that there is only one novel point in the present disclosure. In accordance with the limitations of the multiple claims disclosed by this disclosure, multiple embodiments may be described, and such claims claim that these embodiments protected by them and their equivalents correspond accordingly. Defined in In all instances, the scope of such claims should be considered based on their own advantages in light of the present disclosure, and should not be limited by the headings described herein.

Claims (22)

A body having a nodal region and an abdominal region and configured to propagate ultrasonic waves received in the nodal region along a first direction;
A plurality of direction change features formed in the body, wherein the received ultrasonic waves propagating along the first direction collide with one or more of the direction change features; A direction change feature configured to propagate along a second direction perpendicular to the direction of one,
The body is further configured to stretch and compress along the second direction based on corresponding peaks and troughs of the waves propagating along the second direction;
Comprising at least one ultrasonic welding surface in an abdominal region of the body configured to oscillate based on the stretching and compression;
Ultrasonic sonotrode.   The ultrasonic sonotrode of claim 1, wherein the body comprises the elongated structure having an abdominal region along the long side of the elongated structure and a nodal region along the short side.   The ultrasonic sonotrode according to claim 1, wherein both opposite ends of the sonotrode are provided with the node region, and at least one of the opposite opposite ends is configured to receive the ultrasonic wave.   The ultrasonic sonotrode of claim 3, wherein the redirecting feature comprises an elongated slot formed through the body and extending along the second direction.   The ultrasonic sonotrode according to claim 4, wherein the elongated slots are substantially equally spaced across the body.   The ultrasonic sonotrode of claim 4, wherein the elongate slots each comprise a substantially equal width along each slot length.   The ultrasonic sonotrode of claim 4, wherein the elongated slot comprises various lengths.   The ultrasonic sonotrode according to claim 7, wherein the length of the elongate slot closer to the end of the body is greater than the length of the elongate slot farther from the end of the body.   The thickness of the main body tapers from a central portion of the main body extending along the first direction to an edge of the main body along the second direction. Ultrasonic sonotrode.   The edges of the body each comprise an abdominal region of the body having a substantially uniform thickness along its length, wherein at least one of the abdominal regions includes the at least one welding surface. The ultrasonic sonotrode according to claim 9, comprising:   The central portion of the body comprises a uniform thickness along the first direction, and the taper extends from the central portion of uniform thickness to the edge. Ultrasonic sonotrode. Forming a body having a nodal region and an abdominal region, wherein the body is configured to propagate ultrasonic waves received in the nodal region along a first direction and at least one in the abdominal region Forming with an ultrasonic welding surface;
Forming a plurality of direction change features on the body, wherein the direction change features receive received ultrasonic waves propagating along the first direction, one of the direction change features. Forming, when colliding with one or more, configured to propagate along a second direction perpendicular to the first direction;
The body expands and compresses along the second direction based on the corresponding wave peaks and valleys propagating along the second direction, whereby the body based on the expansion and compression Further configured to oscillate at least one welding surface;
A method for producing an ultrasonic sonotrode.   13. The method of claim 12, wherein forming the body further comprises forming the elongate structure having an abdominal region along the long side of the elongate structure and a nodal region along the short side.   The step of forming the main body further includes the step of forming opposite end portions of the main body as the nodal region, and at least one of the opposite end portions is configured to receive the ultrasonic wave. 12. The method according to 12.   15. The method of claim 14, wherein forming a plurality of redirecting features includes forming an elongated slot that extends through the body and along the second direction.   The method of claim 15, wherein forming the elongate slot further comprises forming the elongate slot substantially equally spaced across the body.   The method of claim 15, wherein forming the elongate slot further comprises forming the elongate slot having a substantially equal width along each slot length.   The method of claim 15, wherein forming the elongated slot further comprises forming the elongated slot to various lengths.   The method of claim 18, wherein the length of the elongate slot closer to the end of the body is greater than the length of the elongate slot farther from the end of the body.   Forming the body includes tapering the thickness of the body from a central portion of the body extending along the first direction to an edge of the body along the second direction. The method of claim 12, further comprising:   Forming the body further comprises forming an edge of the body as an abdominal region having a substantially uniform thickness along its length, wherein at least one of the abdominal regions is 21. The method of claim 20, comprising the at least one welding surface. Forming the body further comprises forming the central portion with a uniform thickness along the first direction, the taper extending from the central portion of uniform thickness to the edge; 21. The method of claim 20, wherein:

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